General purpose 100% solid state drive for direct current rotary machines

ABSTRACT

General purpose 100% solid state Direct Current drive for rotary DC machines with four quadrants operation. It is to say that allows the rotary DC machine to act like motor or generator in the two direction of possible rotation. In the first and third quadrant as motor in both direction of possible rotation, and in the second and fourth quadrant like regenerative brake DC generator, recovering the energy towards the DC network supply. To obtain that generalized control for DC machines of any type, the invention subject of this patent, is based on the interaction of two original ideas that they are: 
         (1) Maintaining the direction of the current in one and only one of the two main windings of the DC machine ( 7 ) either field or armature, by means of a rectifier bridge ( 6 ).    (2) Use a DC controlled power supply ( 14 ), with reversible polarity to feed the complete machine.

BACKGROUND OF THE INVENTION

The present application is based on Chilean Application No. 1792-03, filed on Sep. 4, 2003, the entire contents of which are incorporated herein by reference.

1. Field of the Invention

The present invention relates generally to the field of controlling all type of rotary DC machines.

The present invention is useful mainly for traction application, railways, trains, cranes, tramcars, elevators, electrical stairs, etc. but by no means is limited to such applications.

2. Discussion of the Background

2.1. Field of the Invention

The field of the invention background is to solve the maintenance problem and pour controllability of the actual dc drives mainly applied in the traction applications.

Now a day more and more dc traction system are been replaced by new AC motor with AC drives too, because these last AC technology is more efficient, more affordable, with very high reliability and controllability performance.

Before our invention was not possible le to have one generalized 100% solid state, dc control who can control at the same time the mechanical and electrical variables i.e mechanical as acceleration, speed, breaking power, direction forward reverse and electrical i.e. power, current, voltage, armature and field current, and can regenerate the kinetic energy to the DC supply in breaking operation.

2.2. Discussion of the Background

The application of DC drive is loosing market in the traction industries mainly due to the low efficiency, safety and high labors maintenance that the DC control requirements.

But, migrate from the DC traction system to AC system is very expensive and surely impossible for most of the countries.

For other hands the problems of the DC traction system are mainly in the electrical control used today that use resistances and older contactors with no replaces or spare parts.

If the older DC control of DC traction motors could be replaced by electronic system with equivalent behavior of the AC system the applications of DC motor will be increased because the AC system have one more conversion, then less efficient compared with the DC.

Moreover the AC drives have the problem that must simulate with expensive electronic power circuit a DC series motors to provide high torque at low speed.

SUMMARY OF THE INVENTION

General purpose 100% solid state Direct Current drive for rotary DC machines with four quadrants operation. It is to say that allows the rotary DC machine to act like motor or generator in the two direction of possible rotation. In the first and third quadrant as motor in both direction of possible rotation, and in the second and fourth quadrant like regenerative brake DC generator, recovering the energy towards the DC network supply.

To obtain that generalized control for DC machines of any type, the invention subject of this patent, is based on the interaction of two original ideas that they are:

Maintaining the direction of the current in one and only one of the two main windings of the DC machine either field or armature, by means of a rectifier bridge.

Use a DC controlled power supply, with reversible polarity to feed the complete machine.

BRIEF DESCRIPTION OF THE DRAWING

FIG. A: Typical elementary components of a DC machine

FIG. B: DC power supply with polarity exchange (4) applied to the armature (2) through an internal rectifier (6) in series with the field winding (1.a) who maintain the current direction whatever the polarity be from (4) for controlling series excited DC machines (7).

FIG. C: DC power supply with polarity exchange (4) applied directly to the armature (2) in parallel with an internal rectifier (6) applied to the field windings (1.b) who maintain the current direction whatever the polarity be from (4) for controlling shunt DC machine (8).

FIG. D: DC power supply with polarity exchange (4) applied to the armature (2) through an internal rectifier (6) in series with the field winding (1.a) who maintain the current direction whatever the polarity be from (4) and an independent DC power supply (10) applied to part of the field windings (1.b) for controlling compound excited DC machines (9).

FIG. E: DC power supply with polarity exchange 4) without internal rectifier, for controlling separately excited DC machines (10) feed from an independent DC power supply (11).

FIG. F: Direct current power supply (12) with polarity exchange feed from external AC power supply.

FIG. E: DC power supply with polarity exchange 4) without internal rectifier, for controlling separately excited DC machines (10) feed from an independent DC power supply (11).

FIG. F: Direct current power supply (12) with polarity exchange feed from external AC power supply

FIG. G: DC power supply with polarity exchange (4) connected to AC power supply using a rectifier controlled or not (13)

FIG. H: DC power supply with polarity exchange (4) connected to DC power supply, DC generator, Rectifier, battery, trolley, etc. (17).

FIG. I: DC power supply with polarity exchange (4), like a voltage commutated converter (14), regenerative, connected to DC Power Supply and internal rectifier (6).

FIG. J: DC power supply with polarity exchange (4), like a current commutated converter (15), regenerative, connected to DC Power Supply and internal rectifier (6).

FIG. K: DC power supply with polarity exchange (4), like a voltage commutated converter (14), regenerative, connected to DC Power Supply and internal rectifier (6). with over voltage limiter (16).

FIG. L: DC power supply with polarity exchange (4), like a voltage commutated converter (14), regenerative, connected to DC Power Supply and internal rectifier (6). and dynamic breaker (16), feeding a Series Excitation DC Machine (7)

FIG. M: Simplified topologic diagram for Generalized four quadrant operation DC power supply with polarity exchange (4), like a voltage commutated converter (14), regenerative, connected to DC Power Supply and internal rectifier (6) and dynamic breaker (16), feeding a Series Excitation DC Machine (7)

FIG. N: Operation in first quadrant like motor clockwise rotation, s1 and s2 closed, then open s1 and the current goes through free wheel diode s4, first cycle. FIG. O: Operation in first quadrant like motor, clockwise rotation, s1 and s2 closed, then open s2 and the current goes through free wheel diode s3, second cycle.

FIG. P: Operation in first quadrant like generator, clockwise rotation in regenerative breaking, close s4 and open s1 and s3, controlled short circuit then goes through free wheel diode s2, then open s4, and energy must be injected to the DC supply through diodes s1 and s2, first cycle.

FIG. Q: Operation in first quadrant like generator, clockwise rotation in regenerative breaking, close s3 and open s2 and s4, controlled short circuit then goes through free wheel diode s1, then open s3, and energy must be injected to the DC supply through diodes s1 and s2, first cycle.

FIG. R: Operation in first quadrant like motor clockwise rotation. For anti-clockwise rotation, the firing of the switches (S1, S4) must be interchanged by the firing of the switched (S2, S3) and vice versa.

DIRECT CURRENT MACHINE OR DC MACHINE

The DC machines are equipments who use direct current to make some work. Particularly for electro mechanic energy transfer machines when a DC machines converted electrical energy from a DC supply to mechanic, then it is called “DC motor”, and when the mechanical energy is converted from mechanic to electrical energy then it is called “DC generator.”

The DC machines are composed for at least a field windings, an armature windings and a collector system. The field windings is put in the stator. The armature windings is put in the rotor. The collector system work commutating the current in the armature windings.

Conections of the DC Machines

There are several different connections for DC machines depending the application:

-   -   Series connection or series excitation in witch the field and         armature windings are connected in series. In this case the same         intensity of current flow in the armature and field windings.     -   Parallel connection or shunt excitation in witch the field and         armature windings are connected in parallel. In this case the         voltage between both windings is the same.     -   Independent connection or independent excitation in witch both         windings are connected and fed separately.     -   Compound connection or compound excitation. In this case the         excitation is composed for a low resistance windings section         connected in series with the armature windings and high         resistance windings section connected in parallel with this         series group.         Control of DC Machines

The DC machines have been designed for several application and different current intensities, voltages and rotation speeds. In general to control a DC machines is enough to establish a control loop between the rotation speed and the current flowing trough the armature windings. For changing the rotation direction of a DC machine is necessary to change the direction in only one, either armature windings or field windings.

To control a DC machine, normally have been used of resistors banks, and contactors. With the development of the power electronics semiconductors like older SCR and others, the control of the DC machines every day is getting better. Meanly from the point of view of the efficiency, avoiding the resistors banks to control machine but only for some kind of motor i.e. (separate excitation). However resistors and contactors are still used in the other kind of DC motors.

Problems to Solve for Having Optimum Control of a DC Machine

The problems to solve for improving the control of a DC machine are:

-   -   Improve the efficiency of the actual control systems.     -   Avoid the use of mechanic contactors, relays or electro mechanic         devices due to its high failure rates and also high maintenance         and production costs     -   Improve the availability of the equipment, because the use of         power electronics with semiconductor require less maintenance.     -   Improve the control of the DC machine, mainly in operation modes         such as “motor”, “generator” and direction.         The Invention

The invention, object of this patent is based in the idea that current, in only one of the two DC winding type, either armature or field, the direction of the current must be maintained in all condition of operation, and using a power controller with the capability of inverting polarity.

The condition described before is the result of the use of an “internal rectifier” who maintain the direction of the current in any condition of operation mode in one of the two winding.

The above means that the invention with this characteristic is able to control all kind of DC machine like a motor or a generator, in both direction of rotation and capable to regenerate energy from mechanical to the mains.

Essential Elements or Components of the DC Drive

To obtain that generalized control for DC machines of any type, the invention subject of this patent, is based on the interaction of two original ideas that they are:

-   -   Maintaining the direction of the current in one and only one of         the two main windings of the DC machine either field or         armature, by means of a rectifier bridge at any condition of         operation.     -   Use a DC controlled power supply, with reversible polarity         capability to feed the complete machine.         Direct Current Machine or DC Machine

The DC machines are equipments who use direct current to make some work. Particularly for electro mechanic energy transfer machines when a DC machines converted electrical energy from a DC supply to mechanic, then it is called “DC motor”, and when the mechanical energy is converted from mechanic to electrical energy then it is called “DC generator.”

The DC machines are composed for at least a field windings, an armature windings and a collector system. The field windings is put in the stator. The armature windings is put in the rotor. The collector system work commutating the current in the armature windings.

Conections of the DC Machines

There are several different connections for DC machines depending the application:

-   -   Series connection or series excitation in witch the field and         armature windingss are connected in series. In this case the         same intensity of current flow in the armature and field         windingss.     -   Parallel connection or shunt excitation in witch the field and         armature windingss are connected in parallel. In this case the         voltage between both windingss is the same.     -   Independent connection or independent excitation in witch both         windingss are connected and fed separately.     -   Compound connection or compound excitation. In this case the         excitation is composed for a low resistance windings section         connected in series with the armature windings and high         resistance windings section connected in parallel with this         series group.         Control of DC Machines

The DC machines have been designed for several application and different current intensities, voltages and rotation speeds. In general to control a DC machines is enough to establish a control loop between the rotation speed and the current flowing trough the armature windings. For changing the rotation direction of a DC machine is necessary to change the direction in only one, either armature windingss or field windingss.

To control a DC machine, normally have been used of resistors banks, and contactors. With the development of the power electronics semiconductors like older SCR and others, the control of the DC machines every day is getting better. Meanly from the point of view of the efficiency, avoiding the resistors banks to control machine but only for some kind of motor i.e. (separate excitation). However resistors and contactors are still used in the other kind of DC motors.

Problems to Solve for Having Optimum Control of a DC Machine

The problems to solve for improving the control of a DC machine are:

-   -   Improve the efficiency of the actual control systems.     -   Avoid the use of mechanic contactors, relays or electro mechanic         devices due to its high failure rates and also high maintenance         and production costs     -   Improve the availability of the equipment, because the use of         power electronics with semiconductor require less maintenance.     -   Improve the control of the DC machine, mainly in operation modes         such as “motor”, “generator” and direction.         The Invention

The invention, object of this patent is based in the idea that current, in only one of the two DC winding type, either armature or field, the direction of the current must be maintained in all condition of operation, and using a power controller with the capability of inverting polarity.

The condition described before is the result of the use of an “internal rectifier” who maintain the direction of the current in any condition of operation mode in one of the two winding.

The above means that the invention with this characteristic is able to control all kind of DC machine like a motor or a generator, in both direction of rotation and capable to regenerate energy from mechanical to the mains.

Elements or Components of the Drive

The drive is composed by the interaction of the two following functional elements:

-   -   A current controller with polarity inversion capability.     -   A system which maintain the direction of the current in one of         the two winding either armature or field at any conditions of         operations. 

1. A Power electronic circuit characterized as SOLID STATE DRIVE FOR DIRECT CURRENT MACHINES. The circuit is a composition of switches in one phase bridge connection for voltage commutation related to FIG. 9 or current commutation related to FIG.
 10. Each switch is composed for only one solid state interrupter and a free wheeling diode. Between the terminals with denomination A and B, a one phase rectifier (internal rectifier) bridge which maybe connected in different ways. Between the positive terminal and the negative terminal of the internal rectifier can be connected either or the field winding or the armature winding. Also, between the terminals A and B can be connected either the armature winding or the field winding. The following specific connection are derived of above, series excitation DC machine related FIG. 2, shunt excitation DC machine related FIG. 3, compund excitation DC machine related FIG. 4 and separate excitation DC machine related to the FIG.
 5. The denomination A an B are referential.
 2. A Power electronic circuit characterized as SOLID STATE DRIVE FOR DIRECT CURRENT MACHINES. The circuit is a composition of two (2) rectifiers in antiparallel connection, related to FIG.
 6. Between the terminals with denomination A and B, a one phase rectifier (internal rectifier) bridge which maybe connected in different ways. Between the positive terminal and the negative terminal of the internal rectifier can be connected either or the field winding or the armature winding. Also, between the terminals A and B can be connected either the armature winding or the field winding. The following specific connection are derived of above, series excitation DC machine related FIG. 2, shunt excitation DC machine related FIG. 3, compund excitation DC machine related FIG. 4 and separate excitation DC machine related to the FIG.
 5. The denomination A an B are referential
 3. A Power electronic circuit characterized as SOLID STATE DRIVE FOR DIRECT CURRENT MACHINES. Related to claim N°1 o N°2, in that the control is obtained in an open control loop or a feed back control loop for the armature current of the machine and in secondary feedback loops, the rotation speed, the direction of rotation and the power. All obtained without relay or electro mechanics elements.
 4. A Power electronic circuit characterized as SOLID STATE DRIVE FOR DIRECT CURRENT MACHINES. Related to claim N°1, in that the control in a direct feed back control loop the armature current of the machine and in secondary feedback loops, the rotation speed, the direction of rotation and the power is obtained using the strategy of Pulse Width Modulation (PWM).
 5. A Power electronic circuit characterized as SOLID STATE DRIVE FOR DIRECT CURRENT MACHINES. Related to claim N°2, in that the control in a direct feed back control loop the armature current of the machine and in secondary feedback loops, the rotation speed, the direction of rotation and the power is obtained using the strategy of Firing Phase Delay.
 6. A Power electronic circuit characterized as SOLID STATE DRIVE FOR DIRECT CURRENT MACHINES. Related to claim N°1, N°3 and N°4 in that the PWM control of the machine is obtained by turn-on and turn-off with solid state switches, like SCR, GTO, IGBT, MOSFET, BJT, IGCT, etc., or any other new solid state switch that can appear in the market.
 7. A Power electronic circuit characterized as SOLID STATE DRIVE FOR DIRECT CURRENT MACHINES. Related to claim N°1 until N°6 in that the solid state switches could be connected in series for supporting bigger voltage or in parallel for supporting bigger current.
 8. A Power electronic circuit characterized as SOLID STATE DRIVE FOR DIRECT CURRENT MACHINES. Related to claim N°1 until N°7 in that is possible connect parallel controllers for increasing the power to the DC machine.
 9. A Power electronic circuit characterized as SOLID STATE DRIVE FOR DIRECT CURRENT MACHINES. Related to claim N°1, N°3, N°4, N°6 N°7 and N°8 in that is possible connect in the same DC bar, two or more controllers for several DC machines operating simultaneously in different operation modes, i.e. series, shunt, compound and separate excitation.
 10. A Power electronic circuit characterized as SOLID STATE DRIVE FOR DIRECT CURRENT MACHINES. Related to claim N°1, N°3, N°4, N°6 N°7, N°8 and N°9 in that the power supply could be obtained from a DC generator, a trolley supply or a battery bank.
 11. A Power electronic circuit characterized as SOLID STATE DRIVE FOR DIRECT CURRENT MACHINES. Related to claim N°1, N°3, N°4, N°6 N°7, N°8 and N°9 in that the power supply could be obtained from an AC source with a controlled, semi controlled or not controlled rectifier.
 12. A Power electronic circuit characterized as SOLID STATE DRIVE FOR DIRECT CURRENT MACHINES. Related to claim N°1, N°3, N°4, N°6 N°7, N°8, N°9, N°10 y N°11 in which the capacitor bank connected to the DC bus bar could be only one capacitor or a any combination, series or parallel capacitors.
 13. A Power electronic circuit characterized as SOLID STATE DRIVE FOR DIRECT CURRENT MACHINES. Related to claim N°1, N°3, N°4, N°6 N°7, N°8, N°9, N°10 y N°11 in which the capacitor bank connected DC bus bar could be only one capacitor or a any combination series or parallel capacitors, battery banks, super capacitor or any other electrochemical device for storing energy and increasing the stability of the bus bar DC voltage.
 14. A Power electronic circuit characterized as SOLID STATE DRIVE FOR DIRECT CURRENT MACHINES. Related to claim N°1, N°3, N°4, N°6, N°7, N°8, N°9, N°10, N°11, N°12 y N°13, in that is included a unity called “over voltage limiter”, related to the FIG.
 11. The “over voltage limiter” consume the energy in a resistor bank automatically when detect a DC bus bar over voltage. This over voltage level could be adjustable. The over voltage limiter is composed by at least one switch and one free wheeling diode.
 15. A Power electronic circuit characterized as SOLID STATE DRIVE FOR DIRECT CURRENT MACHINES. Related to claim N°1, N°3, N°4, N°6, N°7, N°8, N°9, N°10, N°11, N°12 y N°13, in that is not included a unity called “over voltage limiter”.
 16. A Power electronic circuit characterized as SOLID STATE DRIVE FOR DIRECT CURRENT MACHINES. Related to claim N°1 until N°15, in that is include a winding or a resistor connected in shunt connection with the field winding of the DC machine, for increasing the rotation speed of the DC machine.
 17. A Power electronic circuit characterized as SOLID STATE DRIVE FOR DIRECT CURRENT MACHINES. Related to claim N°1 until N°15, in that is include a windings or a resistor connected in shunt connection with the field winding of the DC machine, by a controllable switch, for increasing the rotation speed of the DC machine.
 18. A Power electronic circuit characterized as SOLID STATE DRIVE FOR DIRECT CURRENT MACHINES. Related to claim N°1 until N°17, that include a winding or a resistor connected in the terminal A or the terminal B in series with the circuit of the DC machine for avoiding decreasing high dV/dt (surge voltage variations) in the winding of the machine.
 19. A Power electronic circuit characterized as SOLID STATE DRIVE FOR DIRECT CURRENT MACHINES. Related to claim N°1 until N°17, that include a winding or a resistor connected in the terminal A or the terminal B in series and a capacitor in series with the circuit of the DC machine for avoiding decreasing high dV/dt (surge voltage variations) in the windings of the machine.
 20. A Power electronic circuit characterized as SOLID STATE DRIVE FOR DIRECT CURRENT MACHINES. Related to claim N°1 until N°19, that could be used for controlling DC series excitation machines, like FIG. 2 in that the field windings is connected between the positive and negative terminal of the internal rectifier and the armature winding is connected in series with the internal rectifier (and the field windings) between the A and B terminals. In this connection, the DC machine could be controlled changing the position in the circuit of the field windings for the armature windings (and vice-versa).
 21. A Power electronic circuit characterized as SOLID STATE DRIVE FOR DIRECT CURRENT MACHINES. Related to claim N°1 until N°19, that could be used for controlling DC parallel excitation machines, like FIG. 3 in that the field windings is connected between the positive and negative terminal of the internal rectifier and the armature windings is connected in parallel with the internal rectifier (and the field winding) between the A and B terminals. In this connection, the DC machine could be controlled changing the position in the circuit of the field windings for the armature windings (and vice-versa).
 22. A Power electronic circuit characterized as SOLID STATE DRIVE FOR DIRECT CURRENT MACHINES. Related to claim N°1 until N°19, that could be used for controlling DC independent excitation machines, like FIG. 5 in that the armature windings is connected between the A and B terminals. In this connection the field windings could be connected at an independent supply, and the internal rectifier could be not connected.
 23. A Power electronic circuit characterized as SOLID STATE DRIVE FOR DIRECT CURRENT MACHINES. Related to claim N°1 until N°19, that could be used for controlling DC compound excitation machines, like FIG. 4 in that the a low resistance section of the field windings was connected between the positive an negative terminals of the internal rectifier, and the armature windings is connected in series with the internal rectifier between the A and B terminals. A high resistance section of the field windings could be connected at an independent supply.
 24. A Power electronic circuit characterized as SOLID STATE DRIVE FOR DIRECT CURRENT MACHINES. Related to claim N°1 until N°23, that could be used for controlling DC machines in any connection like in the claims N°20 until N°23, in that the machine is used as a motor, i.e., the energy flow from the DC bus bar to its mechanical shaft.
 25. A Power electronic circuit characterized as SOLID STATE DRIVE FOR DIRECT CURRENT MACHINES. Related to claim N°1 until N°23, that could be used for controlling DC machines in any connection like in the claims N°20 until N°23, in that the machine is used as a generator, i.e., the energy flow from its mechanical shaft to the DC bus bar.
 26. A Power electronic circuit characterized as SOLID STATE DRIVE FOR DIRECT CURRENT MACHINES. Related to claim N°1 until N°23, that could be used for controlling DC machines in any connection like in the claims N°20 until N°23, in that the machine is used as a regenerative break, i.e., the energy flow between its mechanical shaft coupled to a rotary mass or mass in movement, i.e. with kinetic energy, to the DC bus bar, recuperating kinetic energy. 